EP2671991B1 - Matelas aléatoire et matériau composite renforcé par fibres - Google Patents

Matelas aléatoire et matériau composite renforcé par fibres Download PDF

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Publication number
EP2671991B1
EP2671991B1 EP20110857745 EP11857745A EP2671991B1 EP 2671991 B1 EP2671991 B1 EP 2671991B1 EP 20110857745 EP20110857745 EP 20110857745 EP 11857745 A EP11857745 A EP 11857745A EP 2671991 B1 EP2671991 B1 EP 2671991B1
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EP
European Patent Office
Prior art keywords
fiber
fibers
random mat
reinforcing
resin
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EP20110857745
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German (de)
English (en)
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EP2671991A4 (fr
EP2671991A1 (fr
Inventor
Yuhei KONAGAI
Katsuyuki Hagihara
Naoaki SONODA
Noboru OKIMOTO
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Teijin Ltd
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Teijin Ltd
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/222—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length characterised by the shape of the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/34—Feeding the material to the mould or the compression means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
    • C08J5/042—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with carbon fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4242—Carbon fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2300/00—Characterised by the use of unspecified polymers
    • C08J2300/22—Thermoplastic resins

Definitions

  • the present invention relates to a random mat usable as a preform of a fiber-reinforced composite material shaped product, and a fiber-reinforced composite material obtained therefrom.
  • Fiber-reinforced composite materials in which carbon fibers, aramid fibers, glass fibers or the like are used as reinforcing fibers have been widely utilized for structural materials, such as aircraft and automobiles, and general industry or sports use, such as tennis rackets, golf club shafts and fishing rods, utilizing high specific strength and specific elasticity modulus thereof.
  • As forms of the reinforcing fibers there are woven fabrics produced by using continuous fibers, UD sheets in which the fibers are aligned unidirectionally, random sheets produced by using cut fibers, nonwoven fabrics and the like.
  • a relatively inexpensive fiber-reinforced composite material can be obtained by using a previously isotropic random mat.
  • This random mat can be obtained by a spray-up (dry production method) wherein spraying cut reinforcing fibers alone or spraying the cut fibers together with a thermosetting resin are performed at the same time into a mold, or a paper-manufacturing (wet method) of adding previously cut reinforcing fibers into an aqueous slurry containing a binder, and followed by paper-making process.
  • dry production method dry production method
  • spraying cut reinforcing fibers alone or spraying the cut fibers together with a thermosetting resin are performed at the same time into a mold
  • a paper-manufacturing (wet method) of adding previously cut reinforcing fibers into an aqueous slurry containing a binder
  • the dry production method there is commonly used a technique of cutting continuous fibers and concurrently spraying the cut fibers, and a rotary cutter is used in many cases.
  • the cut frequency decreases, and thereby results in discontinuous discharge of the fibers from the cutter.
  • the uneven fiber areal weight of the mat locally occurs.
  • the mat having a low fiber areal weight of fibers is prepared, the unevenness in thickness becomes significant, which has caused a problem of deteriorated surface appearance.
  • the fiber-reinforced composite material is obtained by heating and pressurizing a material called a prepreg in which a reinforcing fiber base material is previously impregnated with a thermosetting resin, using an autoclave for 2 hours or more.
  • a prepreg in which a reinforcing fiber base material is previously impregnated with a thermosetting resin
  • an RTM molding method has been proposed in which a base material of reinforcing fibers not impregnated with a resin is set in a mold, and thereafter, a thermosetting resin is poured thereinto, and the molding time has been substantially reduced.
  • the RTM molding method it takes 10 minutes or more until one part is molded.
  • thermoplastic resin generally has high viscosity compared to the thermosetting resin, so that the time to impregnate the molten resin into the fiber base material becomes long. As a result, there has been a problem that the takt time until molding increases.
  • thermoplastic stamping molding This is a molding method in which chopped fibers previously impregnated with a thermoplastic resin are heated to a melting point or more or a flowable temperature or more of the resin and put into a part of a mold, thereafter immediately the mold is closed, and the fibers and the resin are allowed to flow in the mold, thereby obtaining a product shape, followed by cooling to form a shaped product.
  • TP-SMC thermoplastic stamping molding
  • thermoplastic stamping molding the fibers and the resin are allowed to flow in the mold, so that there have been problems of failing to produce a thin-walled one and fiber orientation is disturbed as the orientation becomes beyond control.
  • Patent Document 3 As a means for producing the thin-walled one without allowing the fibers to flow, there is proposed a technique of preparing a thin sheet from reinforcing fibers by a paper-making method, and thereafter, impregnating the sheet with a resin to prepare a prepreg (Patent Document 3).
  • the reinforcing fibers are homogeneously dispersed in an aqueous dispersion, so that the reinforcing fibers are in single fiber form.
  • Patent document 4 discloses a joint body comprising: a reinforcing member having at least one random layer in which a chopped carbon fiber is randomly oriented in a thermoplastic resin, and at least one unidirectional material layer in which a continuous carbon fiber is unidirectionally arranged in a thermoplastic resin; and a reinforced member with an open sectional shape having at least one selected from the group consisting of a random layer and a unidirectional material layer, wherein the reinforcing member and the reinforced member are vibration-welded to form a hollow closed section.
  • Patent document 5 discloses fiber-reinforced thermoplastic resin composition
  • a (meth)acrylic-based polymer has, in a side chain at least one functional group selected from a hydroxyl group, a carboxyl group, an amide group, and an urea group, and has a cohesive energy density (CED) of 385 to 550MPa.
  • CED cohesive energy density
  • the present invention provides, particularly in the case of using a polyolefin-based resin as matrix resin, a fiber-reinforced thermoplastic resin composition and a reinforcing fiber bundle which have high adhesiveness and good mechanical characteristics.
  • Patent document 6 discloses a sheet for stamping molding in which 5 to 300 parts by weight of opened discontinuous inorganic fibers having 3mm or more length are dispersed substantially uniformly based on 100 parts by weight of a thermoplastic synthetic resin powder.
  • Patent document 7 discloses a fiber-reinforced thermoplastic resin molded article, which is a molded article comprising a thermoplastic resin (20% to 65% by weight) and carbon fibers (35% to 80% by weight), wherein the carbon fibers are monofilamentous fibers, the weight-average fiber length (Lw) of the carbon fibers is from 0.5 to 10 mm, and the herein-defined orientation parameter (fp) of the carbon fibers is from -0.25 to 0.25.
  • Patent document 8 discloses a production of fiber formed product for carbon fiber-reinforced carbon composite material, wherein carbon fibers and the powdery matrix material are blown from the Venturi tube together with the air flow into the fiber-loosening and mixing chamber to loosen carbon fibers an mix with the matrix material and the air flow containing the mixture is introduced into the fiber collecting chamber to deposit the loosened fiber mixture on the flat mesh fiber collector, then, the piled-up loosened fiber mixture is hot-pressed to give the objective formed fiber material.
  • the random mat of the invention is characterized in that a thermoplastic matrix resin can be easily impregnated in reinforcing fiber bundles and among single fibers of the reinforcing fibers in the random mat, and thereby being able to provide a fiber-reinforced composite material which is thin in thickness and excellent in mechanical physical properties.
  • thermoplastic matrix resin can be easily impregnated by forming a random mat including a thermoplastic resin and reinforcing fibers satisfying specific bundling or opening conditions, which makes it possible to suitably provide a fiber-reinforced composite material, thus leading to the invention. That is to say, the invention is:
  • the random mat of the invention is preferably usable as a preform for preparing a shaped fiber-reinforced composite material, and a fiber-reinforced composite material excellent in surface appearance quality can be provided thereby. Further, a fiber-reinforced composite material excellent in reduction in thickness and isotropy can be provided by using the random mat of the invention as the preform.
  • the random mat of the invention therefore, can be used as the preform for various constituent members, for example, inner plates, outer plates and constituent members of automobiles, various electric appliances, frames and boxes of machines, and the like.
  • the reinforcing fibers are not oriented in a specific direction, and are spread and arranged in random directions.
  • the random mat of the invention is an in-plane isotropic material.
  • isotropy of the reinforcing fibers in the random mat is also maintained in the shaped product.
  • Isotropy of the random mat and the shaped product therefrom can be quantitatively evaluated by obtaining the shaped product from the random mat and determining the ratio of tensile modulus in two directions at right angles to each other.
  • values of the tensile.modulus in two directions when the ratio obtained by dividing a larger one by a smaller one does not exceed 2, it is evaluated as being isotropic. When the ratio does not exceed 1.3, it is evaluated as being excellent in isotropy.
  • the fiber areal weight of the reinforcing fibers in the random mat is within the range of 25 to 3,000 g/m 2 .
  • the random mat is useful as a prepreg, and various densities can be selected according to desired molding.
  • the reinforcing fibers composing the random mat are discontinuous, and contain reinforcing fibers having a certain range of fiber length, thereby being able to develop a reinforcement function.
  • the fiber length is expressed by the average fiber length determined by measuring the fiber length of the reinforcing fibers in the random mat obtained. Methods for measuring the average fiber length include a method of measuring the fiber length of 100 fibers randomly extracted, down to the order of millimeter, using a caliper or the like, and calculating the average thereof.
  • the average fiber length of the reinforcing fibers in the random mat of the invention is from 5 to 100 mm, preferably from 10 to 100 mm, more preferably from 15 to 100 mm, and still more preferably from 15 to 80 mm. Furthermore, it is most preferably from 20 to 60 mm.
  • the average fiber length of fibers in the mat becomes approximately equivalent to the cut fiber length.
  • the reinforcing fibers composing the random mat are preferably at least one selected from the group consisting of carbon fibers, aramid fibers and glass fibers. These may also be used together, and above all, however, the carbon fibers are preferred in that a composite material light in weight with excellent in strength can be provided.
  • the average fiber diameter is preferably from 3 to 12 ⁇ m, and more preferably from 5 to 7 ⁇ m.
  • the reinforcing fibers there are preferably used ones with a sizing agent adhered thereto, and the sizing agent is preferably from more than 0 to 10 parts by weight based on 100 parts by weight of the reinforcing fibers.
  • single fibers or fiber bundles each comprising single fibers less than the critical single fiber number is present as the reinforcing fibers other than the reinforcing fiber bundles (A).
  • the degree of fiber opening of the reinforcing fiber bundles is controlled to contain the particular fiber bundles of single fibers equal to or more than the specific fiber number and the opened reinforcing fibers other than those at the specific ratio.
  • control can be performed, for example, with the pressure of air blown in a fiber opening step, or the like.
  • control can also be performed by adjusting the size, for example, the width or the fiber number per width of the bundle, of a fiber bundle to be subjected to a cutting step.
  • Preferred conditions will be described below in the section of the fiber opening step.
  • the ratio of the reinforcing fiber bundles (A) to the total amount of fibers is less than 30 vol%, it becomes difficult to obtain a fiber-reinforced composite material excellent in mechanical physical properties when the random mat of the invention is molded, although there is an advantage that a composite material excellent in surface appearance quality is obtained.
  • the ratio of the reinforcing fiber bundles (A) is 90 vol% or more, entangled portions of the fibers become locally thick, resulting in failure to obtain a thin-walled article. This defeats the purpose of the invention.
  • the ratio of the reinforcing fiber bundles (A) is more preferably from 30 vol% to less than 80 vol%.
  • the average number (N) of the single fibers in the reinforcing fiber bundles (A) each comprising the fibers equal to or more than the critical single fiber number satisfies the following formula (2): 0.7 ⁇ 10 4 / D 2 ⁇ N ⁇ 1 ⁇ 10 5 / D 2 wherein D is the average fiber diameter ( ⁇ m) of the single reinforcing fibers.
  • the average number (N) of fibers in the reinforcing fiber bundles (A) each comprising single fibers equal to or more than the critical single fiber number is preferably less than 6x 10 4 /D 2 .
  • control can also be performed by adjusting the size, for example, the width of the bundle or the fiber number per width of the fiber bundle, to be subjected to a cutting step, in a preferred production method described later.
  • the size for example, the width of the bundle or the fiber number per width of the fiber bundle
  • control can also be performed by adjusting the size, for example, the width of the bundle or the fiber number per width of the fiber bundle, to be subjected to a cutting step, in a preferred production method described later.
  • Specific examples thereof include a method of widening the width of the fiber bundle by fiber extending or the like, followed by subjecting to the cutting step, and a method of providing a slitting step before the cutting step.
  • the fiber bundle may be slit at the same time as being cut.
  • the critical single fiber number is from 86 to 120.
  • the average number of fibers in the fiber bundles is within the range of from more than 280 to less than 4,000. Above all, it is preferably from 600 to 2,500, and more preferably from 600 to 1,600.
  • the average fiber diameter of carbon fibers is 7 ⁇ m, the average number of fibers in the fiber bundle is within the range of from more than 142 to less than 2,040. Above all, it is preferably from 300 to 1,500, and more preferably from 300 to 800.
  • the average number (N) of fibers in the reinforcing fiber bundles (A) is 0.7 ⁇ 10 4 /D 2 or less, it becomes difficult to obtain a composite material having high fiber volume content (Vf). Further, when the average number (N) of fibers in the reinforcing fiber bundles (A) is 1 ⁇ 10 5 /D 2 or more, thick portions locally may occur in composite materials, which is liable to cause voids.
  • the random mat of the invention can be adjusted to various thicknesses, and by using this one as a preform, a thin-walled shaped product having a thickness of about 0.2 to 1 mm can also be suitably obtained. That is to say, according to the invention, the random mat tailored to the thickness of various desired shaped products can be prepared, and is useful as a preform for a thin shaped product, particularly such as a surface layer of a sandwich material.
  • the random mat of the invention contains a solid thermoplastic resin, and becomes a preform for obtaining a fiber-reinforced composite material.
  • the thermoplastic resin is preferably present in fibrous and/or particulate form.
  • the reinforcing fibers and the thermoplastic resin in fibrous and/or particulate form are present in a mixed state, which makes it unnecessary to allow the reinforcing fibers and the resin to flow in a mold, and the thermoplastic resin can be easily impregnated in the reinforcing fiber bundles and spaces between single fibers of the reinforcing fibers at the time of molding.
  • the thermoplastic resin is preferably formed in fibrous and/or particulate form. Two or more kinds of thermoplastic resins may be used, and further, fibrous and particulate ones may be used together.
  • the fineness thereof is preferably from 100 to 5,000 dtex, and more preferably from 1,000 to 2,000 dtex.
  • the average length thereof is preferably from 0.5 to 50 mm, and more preferably from 1 to 10 mm.
  • a spherical form a strip form or a cylindrical form such as a pellet.
  • a body of revolution of a perfect circle or an ellipse, or a shape such as egg form.
  • the average particle size is preferably from 0.01 to 1,000 ⁇ m, more preferably from 0.1 to 900 ⁇ m and still more preferably from 1 to 800 ⁇ m, although there is no particular limitation on particle size distribution, sharp distribution is more preferred for the purpose of obtaining a thinner shaped product. However, desired particle size distribution obtained by an operation such as classification can be used.
  • a cylindrical form such as a pellet, a prismatic form or a scale form, and a rectangular form obtained by finely cutting a film is also preferred.
  • a certain degree of aspect ratio may be allowed, but the preferred length thereof shall be considered to be in the same range as in the case of the above-mentioned fibrous form.
  • thermoplastic resins include, for example, a polyvinyl chloride resin, a polyvinylidene chloride resin, a vinyl acetate resin, a polyvinyl alcohol resin, a polystyrene resin, an acrylonitrile-styrene resin (AS resin), an acrylonitrile-butadiene-styrene resins (ABS resin), an acrylic resin, a methacrylic resin, a polyethylene resin, a polypropylene resin, a polyamide 6 resin, a polyamide 11 resin, a polyamide 12 resin, a polyamide 46 resin, a polyamide 66 resin, a polyamide 610 resin, a polyacetal resin, a polycarbonate resin, a polyethylene terephthalate resin, a polyethylene naphthalate resin, a polybutylene terephthalate resin, a polybutylene naphthalate resin, a polyarylate resin, a polyphenylene ether resin, a poly
  • the existing amount of the thermoplastic resin in the random mat is preferably from 50 to 1,000 parts by weight based on 100 parts by weight of the reinforcing fibers- It is more preferably from 55 to 500 parts by weight based on 100 parts by weight of the reinforcing fibers, and still more preferably from 60 to 300 parts by weight based on 100 parts by weight of the reinforcing fibers.
  • the random mat of the invention may contain additives such as various fibrous or non-fibrous fillers made from organic or inorganic fibers, a flame retardant, a UV-resistant agent, a pigment, a release agent, a softening agent, a plasticizer and a surfactant, within the range not impairing the object of the invention.
  • additives such as various fibrous or non-fibrous fillers made from organic or inorganic fibers, a flame retardant, a UV-resistant agent, a pigment, a release agent, a softening agent, a plasticizer and a surfactant, within the range not impairing the object of the invention.
  • the random mat of the invention is preferably produced by the following steps 1 to 4.
  • the invention includes a method for producing a random mat including the above-mentioned steps 1 to 4. The respective steps will be described in detail below.
  • a method for cutting the reinforcing fibers in the method of the invention is specifically the step of cutting the reinforcing fiber bundles by using a knife.
  • a knife used for cutting
  • the knife used for cutting there is preferred a rotary cutter or the like.
  • the rotary cutter there is preferred one provided with a spiral knife or a so-called fiber separating knife in which many short blades are arranged.
  • a specific schematic view of the cutting step is shown in Fig. 1 .
  • One example of the rotary cutter having the spiral knife is shown in Fig. 2
  • one example of the rotary cutter having the fiber separating knife is shown in Fig. 3 .
  • control is preferably performed by adjusting the size of a fiber bundle, for example, the width of the bundle or the fiber number per width, to be subjected to the cutting step.
  • the reinforcing fiber bundle previously having a fiber number within the range of formula (2) is preferably used.
  • the fiber bundle is preferably subjected to the cutting step after adjusting the width or the fiber number per width of the fiber bundle to be subjected to the cutting step. Specific examples thereof include a method of thinly spreading the fiber bundle by opening or the like to widen the width thereof, followed by subjecting to the cutting step, and a method of providing a slitting step of fiber bundles before the cutting step.
  • the fiber bundle is subjected to the cutting step after the fiber bundle has been previously fined by slitting.
  • an ordinary flat blade, a spiral blade or the like having no special mechanism can be used as the cutter, accordingly,
  • examples thereof include a method of cutting the fiber bundle by using the fiber separating knife and a method of slitting the fiber bundle at the same time as cutting it by using a cutter having a slitting function.
  • the average number (N) of fibers can be decreased by using one having a narrow knife width, and conversely, the average number (N) of fibers can be increased by using one having a wide knife width.
  • a fiber separating cutter with blades having the slitting function which are parallel to a fiber direction, in addition to blades perpendicular to the fiber direction, is shown in Fig. 4 .
  • short blades perpendicular to the fiber direction are spirally provided at certain intervals, and at the same time as being cut by these, the fibers can be slit by the blades parallel to the fiber direction.
  • blades parallel to the fiber direction may also be provided between the fiber separating knives.
  • the local unevenness in fiber areal weight of fibers has a significant effect.
  • a rotary cutter in which an ordinary flat blade is arranged, the fibers are discontinuously cut.
  • the unevenness occurs in the mat. Accordingly, it is possible to produce a mat with a small unevenness in fiber areal weight of fibers by continuously cutting the fibers without interruption by using a knife with an angle defined. That is to say, for the purpose of continuously cutting the reinforcing fibers, the knife is preferably arranged on the rotary cutter regularly at a specific angle.
  • the pitch of the blades in the circumferential direction is reflected as such in the fiber length of the reinforcing fibers.
  • Figs. 2 to 4 are examples of the knives in which the angle is defined as described above, and the angle ⁇ between the circumferential direction and the arranging direction of the knife in these cutters is shown in the figures.
  • the fiber opening step in the method of the invention is a step of opening a fiber bundle by introducing the cut reinforcing fiber bundles into a tube and blowing air to the fibers.
  • the degree of fiber opening, the existing amount of the reinforcing fiber bundles (A) and the average number (N) of single fibers in the reinforcing fiber bundles (A) can be appropriately controlled by the pressure of air or the like.
  • the reinforcing fibers can be opened by directly blowing air to the fiber bundle at a wind velocity of 1 to 1,000 m/sec preferably through compressed air blowing holes.
  • the wind velocity is preferably from 5 to 500 m/sec, and more preferably from more than 50 to 500 m/sec.
  • holes having a diameter of about 1 to 2 mm are made in several places in the tube through which the reinforcing fibers pass, and a pressure of 0.01 to 1.0 MPa, more preferably about 0.2 to 0.8 MPa, is applied from the outside to directly blow compressed air to the fiber bundle.
  • the fiber bundle can be more remained by decreasing the wind velocity, and conversely, the fiber bundle can be opened to single fiber form by increasing the wind velocity.
  • the application step in the method of the invention is constituted by steps of suctioning the opened reinforcing fibers, together with the fibrous or particulate thermoplastic resin, at the same time as spreading them, and spraying the reinforcing fibers and the thermoplastic resin at the same time.
  • the opened reinforcing fibers and the fibrous or particulate thermoplastic resin are applied onto a sheet, specifically onto a breathable sheet mounted in a lower portion of a fiber opening machine, preferably at the same time.
  • the supply amount of the thermoplastic resin is preferably from 50 to 1,000 parts by weight based on 100 parts by weight of the reinforcing fibers.
  • the thermoplastic resin is more preferably from 55 to 500 parts by weight based on 100 parts by weight of the reinforcing fibers, and still more preferably from 60 to 300 parts by weight based on 100 parts by weight of the reinforcing fibers.
  • the reinforcing fibers and the fibrous or particulate thermoplastic resin are preferably sprayed so as to be two-dimensionally oriented herein.
  • an application method and the following fixing method become important.
  • the application method of the reinforcing fibers it is preferred to use a taper tube of a conical shape or the like. In the tube of a circular cone or the like, air is diffused to decrease the flow rate in the tube, and at this time, rotational force is given to the reinforcing fibers.
  • the reinforcing fibers opened in the taper tube by utilizing this Venturi effect can be preferably spread and sprayed.
  • the following fixing step and the application step may be performed at the same time, that is to say, the fibers may be fixed while being applied and deposited. It is preferred that the fibers are sprayed on a movable breathable sheet having a suction mechanism to deposit them in mat form, followed by fixing thereof in that state.
  • the breathable sheet is constituted by a conveyer comprising a net, and the fibers are deposited thereon while continuously moving it in one direction, the random mat can be continuously formed. Further, the breathable sheet may be moved back and forth and around, thereby achieving uniform deposition.
  • a leading edge of an application (spraying) unit of the reinforcing fibers and the thermoplastic resin is reciprocated in a direction perpendicular to the moving direction of the continuously moving breathable support, and thereby continuously performing the application and the fixing.
  • the reinforcing fibers and the thermoplastic resin are preferably uniformly sprayed without unevenness in the random mat.
  • the fixing step in the method of the invention is a step of fixing the applied reinforcing fibers and thermoplastic resin.
  • air is suctioned from a lower portion of the breathable sheet to fix the fibers.
  • the thermoplastic resin sprayed together with the reinforcing fibers is also fixed while being mixed, by air suction in the case of fibrous form or together with the reinforcing fibers even in the case of particulate form.
  • the highly two-dimensionally oriented mat can be obtained by suctioning from the lower portion through the breathable sheet.
  • the particulate or fibrous thermoplastic resin can be suctioned using negative pressure generated, and furthermore, easily mixed with the reinforcing fibers by diffusion flux generated in the tube.
  • the moving distance of the resin is short in an impregnating step by the presence of the thermoplastic resin in the vicinity of the reinforcing fibers, so that it is possible to impregnate the resin into the mat for a relatively short period of time.
  • the random mat made of fibers orientated two-dimensionally and containing few fibers whose long axes are three-dimensionally oriented.
  • the application step and the fixing step may be performed at the same time. Also, when the random mat is industrially produced, the application and the fixing are preferably performed at the same time while moving the breathable sheet. Further, it is also preferred that the leading edge of the application (spraying) unit of the reinforcing fibers and the thermoplastic resin is reciprocated in a direction perpendicular to the moving direction of the continuously moving breathable support, and thereby continuously performing the application and the fixing.
  • the random mat of the invention is molded as a preform, and thereby being able to obtain a fiber-reinforced composite material comprising the reinforcing fibers and the thermoplastic resin.
  • molding methods press molding and/or thermoforming are preferred.
  • the random mat of the invention is characterized by being easily impregnated with a thermoplastic resin, so that molding is performed by hot press molding or the like to be able to efficiently obtain the fiber-reinforced composite material.
  • the thermoplastic resin in the random mat is melted under pressure and impregnated in the reinforcing fiber bundles and spaces between the single fibers of the reinforcing fibers, followed by cooling to perform molding.
  • the plate-like fiber-reinforced composite material can be efficiently obtained for a short period of time.
  • the plate-like fiber-reinforced composite material is further useful as a prepreg for three-dimensional molding, particularly as a prepreg for press molding.
  • the shaped product can be obtained by so-called cold press in which the plate-like fiber-reinforced composite material sheet is heated to the melting point or higher, or to the glass transition temperature or higher of the resin, and alone or a plurality of the sheets stacked in accordance with the shape of the shaped product to be obtained are put in a mold and kept at a temperature lower than the melting point or lower than the glass transition temperature of the resin, pressurized and thereafter cooled.
  • the shaped product can be obtained by so-called hot press in which the plate-like fiber-reinforced composite material is put into a mold, press molding is performed while elevating the temperature to the melting point or higher or to the glass transition temperature or higher, and then, the mold is cooled to a temperature lower than the melting point or lower than the glass transition temperature.
  • the invention includes the fiber-reinforced composite material obtained from the random mat.
  • the reinforcing fibers and the thermoplastic resin are mixed and present close to each other, so that thermoplastic resin can be easily impregnated without necessity of allowing the fibers and the resin to flow in the mold.
  • the fiber-reinforced composite material obtained from the random mat of the invention it becomes possible to keep the configuration of the reinforcing fibers, that is, isotropy. Further, the degree of fiber opening of the reinforcing fibers in the random mat is also appropriately maintained in the fiber-reinforced composite material.
  • the average fiber length and fiber bundles of the reinforcing fibers in the composite material can be measured in the same manner as in the random mat, after the resin is removed from the composite material.
  • a random mat is cut out to a size of about 100 mm ⁇ 100 mm.
  • Fiber bundles are all taken out with a tweezer from the mat which have been cut out, and the bundle number (I) of the reinforcing fiber bundles (A) and the length (Li) and weight (Wi) of the fiber bundles are measured and recorded.
  • the weight (Wk) thereof is finally measured as a whole.
  • a balance which is measurable down to 1/100 mg is used.
  • the critical single fiber number is calculated, and division into the reinforcing fiber bundles (A) comprising single fibers equivalent to or more than the critical single fiber number and the others is performed.
  • division is performed for each kind of fibers, and the measurement and the evaluation are performed for each.
  • a determination method the average number (N) of fibers in the reinforcing fiber bundles (A) is as follows.
  • thermoplastic resin For a molded plate, namely the reinforcing fiber composite material of the invention, after a thermoplastic resin is removed in a furnace at 500°C for about 1 hour, measurement is performed in the same manner as the above-mentioned method in the random mat.
  • reinforcing fibers there were used a strand of carbon fibers, "Tenax" (registered trade mark) STS40-24KS (average fiber diameter: 7 ⁇ m, strand width: 10 mm) manufactured by Toho Tenax Co., Ltd., and the strand was widened to a width of 20 mm.
  • a cutting device there was used a rotary cutter in which a spiral knife was arranged on a surface thereof, using a cemented carbide.
  • ⁇ in the following formula (3) was 63 degrees, and the pitch of blades was adjusted to 10 mm so as to cut the reinforcing fibers to a fiber length of 10mm.
  • Pitch of blades width of a reinforcing fiber strand ⁇ tan 90 - ⁇ wherein ⁇ is the angle between the circumferential direction and the knife.
  • SUS 304-made nipples different in diameter were welded to prepare a double tube and small holes were made in an inner tube. Compressed air was supplied between the inner tube and an outer tube using a compressor. At this time, the wind velocity of air from the small holes was 450 m/sec.
  • This tube was disposed just under the rotary cutter, and further, a taper tube was welded to a lower portion thereof. A matrix resin was supplied from a side face of the taper tube.
  • the matrix resin there were used particles obtained by freeze-pulverizing pellets of a polycarbonate, "Panlite” (registered trade mark) L-1225L manufactured by Teijin Chemicals Ltd., followed by further classification through a 20 mesh and a 100 mesh.
  • the average particle size of the polycarbonate powder was about 710 ⁇ m.
  • a table movable in XY directions was installed under an outlet of the taper tube, and suctioning was performed from a lower portion of the table with a blower. Then, the supply amount of the reinforcing fibers was set to 180 g/min, and the supply amount of the matrix resin was set to 480 g/min.
  • the system was operated to obtain a random mat in which the reinforcing fibers and the thermoplastic resin were mixed.
  • the configuration of the reinforcing fibers in the random mat was observed.
  • fibers were randomly dispersed in the plane and the fiber axes were approximately parallel to a plane.
  • the average fiber length of the reinforcing fibers of the resulting random mat was 10 mm, and the fiber areal weight of fibers was 200 g/m 2 .
  • the ratio of the reinforcing fiber bundles (A) and the average number (N) of fibers were examined.
  • the critical single fiber number defined by formula (1) was 86.
  • the ratio thereof to the total amount of fibers in the mat was 35%, and the average number (N) of fibers in the reinforcing fiber bundles (A) was 240.
  • the polycarbonate powder was dispersed among the reinforcing fibers in a state having no large unevenness.
  • the resulting random mat was heated in a press machine heated at 300°C, at 1 MPa for 3 minutes to obtain a molded plate (the fiber-reinforced composite material of the invention, hereinafter the molded plate) having a thickness of 0.6 mm.
  • a molded plate the fiber-reinforced composite material of the invention, hereinafter the molded plate
  • an ultrasonic inspection was performed. As a result, a non-impregnated portion or a void was not observed.
  • the ratio of the reinforcing fiber bundles (A) to the total amount of fibers was 35%, and the average number (N) of fibers in the reinforcing fiber bundles (A) was 240. Differences from the above-mentioned measurement results of the random mat were not observed.
  • reinforcing fibers there were used carbon fiber strands, "Tenax" (registered trade mark) IMS60-12K (average fiber diameter: 5 ⁇ m, strand width: 6 mm) manufactured by Toho Tenax Co., Ltd.
  • a cutting device there was used a rotary cutter in which a spiral knife was arranged on a surface thereof, using a cemented carbide.
  • a fiber separating cutter in which blades parallel to a fiber direction as shown in Fig. 4 were provided at 0.5-mm intervals, for the purpose of miniaturizing the fiber bundles.
  • ⁇ in the above-mentioned formula (3) was 17 degrees, and the pitch of blades was adjusted to 20 mm.
  • the reinforcing fibers were cut to a fiber length of 20 mm.
  • a tube having small holes was prepared, and compressed air was supplied thereto using a compressor. The wind velocity of air from the small holes was adjusted to 150 m/sec.
  • This tube was disposed just under the rotary cutter, and further, a taper tube was welded to a lower portion thereof.
  • a matrix resin was supplied from a side face of the taper tube.
  • PA 66 fibers T5 Nylon manufactured by Asahi Kasei Fibers Corp., fineness: 1,400 dtex
  • a table movable in XY directions was installed under an outlet of the taper tube, and suctioning was performed from a lower portion of the table with a blower. Then, the supply amount of the reinforcing fibers was set to 1,000 g/min, and the supply amount of the matrix resin was set to 3,000 g/min. The system was operated to obtain a random mat in which the reinforcing fibers and the polyamide were mixed. The configuration of the reinforcing fibers in the random mat was observed. As a result, the fiber axes of the reinforcing fibers were approximately parallel to a plane, and randomly dispersed in the plane. The average fiber length of the reinforcing fibers of the resulting random mat was 20 mm, and the fiber areal weight of fibers was 1,000 g/m 2 .
  • the ratio of the reinforcing fiber bundles (A) and the average number (N) of fibers were examined.
  • the critical single fiber number defined by formula (1) was 120.
  • the ratio thereof to the total amount of fibers in the mat was 86%
  • the average number (N) of fibers in the reinforcing fiber bundles (A) was 900.
  • the nylon fibers were dispersed in the reinforcing fibers in a state having no large unevenness.
  • the resulting random mat was heated in a press machine heated at 280°C, at 1.0 MPa for 3 minutes to obtain a molded plate having a thickness of 3.2 mm.
  • a press machine heated at 280°C, at 1.0 MPa for 3 minutes to obtain a molded plate having a thickness of 3.2 mm.
  • an ultrasonic inspection was performed for the resulting molded plate. As a result, a non-impregnated portion or a void was not recognized.
  • the ratio of the reinforcing fiber bundles (A) to the total amount of fibers was 86%, and the average number (N) of fibers in the reinforcing fiber bundles (A) was 900. Differences from the above-mentioned measurement results of the random mat were not observed.
  • As reinforcing fibers there were used glass fiber strands, EX-2500 (average fiber diameter: 15 ⁇ m, strand width: 9 mm) manufactured by Nippon Electric Glass Co., Ltd.
  • As a cutting device there was used a rotary cutter in which short blades in a 90-degree direction to the fibers were obliquely disposed and a fiber separating knife was arranged on a surface thereof, using a cemented carbide. The width of the knife was 1 mm, and further, blades parallel to a fiber direction were provided between the knives, for the purpose of miniaturizing the fiber bundles.
  • ⁇ in the above-mentioned formula (3) was 10 degrees, and the pitch of blades was adjusted to 50 mm.
  • the reinforcing fibers were cut to a fiber length of 50 mm.
  • a fiber opening device there was used the same device as used in Example 1.
  • the wind velocity of air from the small holes was adjusted to 350 m/sec by decreasing the pressure of the compressor.
  • This tube was disposed just under the rotary cutter, and further, a taper tube was welded to a lower portion thereof.
  • a matrix resin was supplied from a side face of the taper tube.
  • this matrix resin there was used a powder obtained by freeze-pulverizing pellets of a polycarbonate, "Panlite" (registered trade mark) L-1225L manufactured by Teijin Chemicals Ltd., followed by further classification through a 30 mesh and a 200 mesh. At this time, the average particle size thereof was about 360 ⁇ m.
  • a table movable in XY directions was installed under an outlet of the taper tube, and suctioning was performed from a lower portion of the table with a blower. Then, the supply amount of the reinforcing fibers was set to 300 g/min, and the supply amount of the matrix resin was set to 600 g/min.
  • the system was operated to obtain a random mat in which the reinforcing fibers and the thermoplastic resin were mixed. The configuration of the reinforcing fibers in the random mat was observed. As a result, the fiber axes of the reinforcing fibers were approximately parallel to a plane, and randomly dispersed in the plane. The average fiber length of the reinforcing fibers of the resulting random mat was 50 mm, and the fiber areal weight of fibers was 300 g/m 2 .
  • the ratio of the reinforcing fiber bundles (A) and the average number (N) of fibers were examined.
  • the critical single fiber number defined by formula (1) was 40.
  • the ratio thereof to the total amount of fibers in the mat was 68%, and the average number (N) of fibers in the reinforcing fiber bundles (A) was 60.
  • the polycarbonate powder was dispersed in the reinforcing fibers in a state having no large unevenness.
  • This random mat was heated in a press machine heated at 300°C, at 1.0 MPa for 3 minutes to obtain a molded plate having a thickness of 0.6 mm.
  • a press machine heated at 300°C, at 1.0 MPa for 3 minutes to obtain a molded plate having a thickness of 0.6 mm.
  • an ultrasonic inspection was performed. As a result, a non-impregnated portion or a void was not confirmed.
  • reinforcing fibers there were used carbon fiber strands, "Tenax" (registered trade mark) STS40-24KS (average fiber diameter: 7 ⁇ m, strand width: 10 mm) manufactured by Toho Tenax Co., Ltd., which was opened to a width of 30 mm.
  • a cutting device there was used a rotary cutter in which a spiral knife was arranged on a surface thereof, using a cemented carbide. At this time, ⁇ in the above-mentioned formula (3) was 45 degrees, and the pitch of blades was adjusted to 30 mm so as to cut the reinforcing fibers to a fiber length of 30 mm.
  • the average particle size of the polycarbonate powder was about 710 ⁇ m.
  • a table movable in XY directions was installed under an outlet of the taper tube, and suctioning was performed from a lower portion of the table with a blower.
  • the supply amount of the reinforcing fibers was set to 1,000 g/min
  • the supply amount of the matrix resin was set to 1,100 g/min.
  • the system was operated to obtain a random mat in which the reinforcing fibers and the thermoplastic resin were mixed.
  • the configuration of the reinforcing fibers in the random mat was observed.
  • the fiber axes of the reinforcing fibers were approximately parallel to a plane, and randomly dispersed in the plane.
  • the average fiber length of the reinforcing fibers of the resulting random mat was 30 mm, and the fiber areal weight of fibers was 1,000 g/m 2 .
  • the ratio of the reinforcing fiber bundles (A) and the average number (N) of fibers were examined.
  • the critical single fiber number defined by formula (1) was 86.
  • the ratio thereof to the total amount of fibers in the mat was 60%, and the average number (N) of fibers in the reinforcing fiber bundles (A) was 1,620.
  • the polycarbonate powder was dispersed in the reinforcing fibers in a state having no large unevenness.
  • reinforcing fibers there were used carbon fiber strands, "Tenax" (registered trade mark) STS40-24KS (average fiber diameter: 7 ⁇ m, strand width: 10 mm) manufactured by Toho Tenax Co., Ltd., which was opened to a fiber width of 20 mm.
  • a cutting device there was used a rotary cutter in which a spiral knife was arranged on a surface thereof, using a cemented carbide.
  • ⁇ in the above-mentioned formula (3) was 68 degrees, and the pitch of blades was adjusted to 8 mm so as to cut the reinforcing fibers to a fiber length of 8 mm.
  • the average particle size of the polycarbonate powder was about 710 ⁇ m.
  • a table movable in XY directions was installed under an outlet of the taper tube, and suctioning was performed from a lower portion of the table with a blower.
  • the supply amount of the reinforcing fibers was set to 1,200 g/min
  • the supply amount of the matrix resin was set to 1,600 g/min.
  • the system was operated to obtain a random mat in which the reinforcing fibers and the thermoplastic resin were mixed.
  • the configuration of the reinforcing fibers in the random mat was observed.
  • the fiber axes of the reinforcing fibers were approximately parallel to a plane, and randomly dispersed in the plane.
  • the average fiber length of the reinforcing fibers of the resulting random mat was 8 mm, and the fiber areal weight of fibers was 1,200 g/m 2 .
  • the ratio of the reinforcing fiber bundles (A) and the average number (N) of fibers were examined.
  • the critical single fiber number defined by formula (1) was 86.
  • the ratio thereof to the total amount of fibers in the mat was 38%, and the average number (N) of fibers in the reinforcing fiber bundles (A) was 220.
  • the polycarbonate powder was dispersed in the reinforcing fibers in a state having no large unevenness.
  • the resulting random mat was heated in a press machine heated at 300°C, at 1 MPa for 3 minutes to obtain a molded plate having a thickness of 1.9 mm.
  • a press machine heated at 300°C, at 1 MPa for 3 minutes to obtain a molded plate having a thickness of 1.9 mm.
  • an ultrasonic inspection was performed for the resulting molded plate. As a result, a non-impregnated portion or a void was not recognized.
  • reinforcing fibers there were used carbon fiber strands, "Tenax" (registered trade mark) STS40-24KS (average fiber diameter: 7 ⁇ m, strand width: 10 mm, tensile strength: 4,000 MPa) manufactured by Toho Tenax Co., Ltd., which was widened to a width of 30 mm.
  • a slitter in which disc-like blades prepared using a cemented carbide were arranged at 1-mm intervals.
  • a rotary cutter in which a spiral knife was arranged on a surface thereof, using a cemented carbide.
  • ⁇ in the above-mentioned formula (3) was 45 degrees, and the pitch of blades was adjusted to 30 mm so as to cut the reinforcing fibers to a fiber length of 30 mm.
  • SUS 304-made nipples different in diameter were welded to prepare a double tube and small holes were made in an inner tube. Compressed air was supplied between the inner tube and an outer tube of the device using a compressor. At this time, the wind velocity of air from the small holes was 350 m/sec.
  • This tube was disposed just under the rotary cutter, and further, a taper tube was welded to a lower portion thereof. A matrix resin was supplied from a side face of the taper tube.
  • this matrix resin there were used particles obtained by freeze-pulverizing pellets of a polycarbonate, "Panlite” (registered trade mark) L-1225L manufactured by Teijin Chemicals Ltd., followed by further classification through a 20 mesh and a 100 mesh.
  • the average particle size of the polycarbonate powder was about 710 ⁇ m.
  • a table movable in XY directions was installed under an outlet of the taper tube, and suctioning was performed from a lower portion of the table with a blower. Then, the supply amount of the reinforcing fibers was set to 500 g/min, and the supply amount of the matrix resin was set to 550 g/min.
  • the system was operated to obtain a random mat in which the reinforcing fibers and the thermoplastic resin were mixed.
  • the configuration of the reinforcing fibers in the random mat was observed.
  • the fiber axes of the reinforcing fibers were approximately parallel to a plane, and randomly dispersed in the plane.
  • the average fiber length of the reinforcing fibers of the resulting random mat was 30 mm, and the fiber areal weight of fibers was 500 g/m 2 .
  • the ratio of the reinforcing fiber bundles (A) and the average number (N) of fibers were examined.
  • the critical single fiber number defined by formula (1) was 86.
  • the ratio thereof to the total amount of fibers in the mat was 35%, and the average number (N) of fibers in the reinforcing fiber bundles (A) was 270.
  • the polycarbonate powder was dispersed in the reinforcing fibers in a state having no large unevenness.
  • reinforcing fibers there were used carbon fiber strands, "Tenax" (registered trade mark) STS40-24KS (average fiber diameter: 7 ⁇ m, strand width: 10 mm) manufactured by Toho Tenax Co., Ltd., which was widened in width to 30 mm.
  • a fiber separating device there was used a slitter in which disc-like blades prepared using a cemented carbide were arranged at 0.5-mm intervals.
  • As a cutting device there was used a rotary cutter in which a spiral knife made of cemented carbide was arranged on a surface thereof. At this time, ⁇ in the above-mentioned formula (3) was 45 degrees, and the pitch of blades was adjusted to 30 mm so as to cut the reinforcing fibers to a fiber length of 30 mm.
  • a strand which passed through the cutter was introduced into a flexible conveying pipe disposed just under the rotary cutter, followed by introduction thereof into a fiber opening device.
  • a fiber opening device a double tube prepared by welding SUS 304-made nipples different in diameter was used. Small holes were made in an inner tube of the double tube, and compressed air was supplied between the inner tube and an outer tube using a compressor. At this time, the wind velocity of air from the small holes was 100 m/sec. A taper tube increased in diameter downwardly was welded to a lower portion of this tube.
  • a nylon resin "A1030" manufactured by Unitika Ltd.
  • a breathable support hereinafter referred to as a fixing net
  • suctioning was performed from a lower portion thereof with a blower.
  • a mixture of the cut reinforcing fibers and the nylon resin was deposited in band form on that fixing net while reciprocating the flexible conveying pipe and the taper tube in the width direction.
  • the supply amount of the reinforcing fibers was set to 500 g/min
  • the supply amount of the matrix resin was set to 530 g/min.
  • the system was operated to obtain a random mat in which the reinforcing fibers and the thermoplastic resin were mixed, on the support.
  • the configuration of the reinforcing fibers in the random mat was observed.
  • the fiber axes of the reinforcing fibers were approximately parallel to a plane, and randomly dispersed in the plane.
  • the average fiber length of the reinforcing fibers of the resulting random mat was 30 mm, and the fiber areal weight of fibers was 500 g/m 2 .
  • the ratio of the reinforcing fiber bundles (A) and the average number (N) of fibers were examined.
  • the critical single fiber number defined by formula (1) was 86.
  • the ratio thereof to the total amount of fibers in the mat was 85%, and the average number (N) of fibers in the reinforcing fiber bundles (A) was 370.
  • the nylon powder was being dispersed in the reinforcing fibers in a state having no large unevenness.
  • a random mat was prepared in the same manner as in Example 1 with the exception that the wind velocity of air from the small holes was adjusted to 50 m/sec. The configuration of the reinforcing fibers in the random mat was observed. As a result, the fiber axes of the reinforcing fibers were approximately parallel to a plane, and randomly dispersed in the plane.
  • the ratio of the reinforcing fiber bundles (A) and the average number (N) of fibers were examined.
  • the critical single fiber number defined by formula (1) was 86.
  • the ratio thereof to the total amount of fibers in the mat was 95%, and the average number (N) of fibers in the reinforcing fiber bundles (A) was 1,500.
  • the reinforcing fiber bundles of the resulting random mat were thick, and a molded plate was prepared using this random mat in the same manner as in Example 1, and subjected to the ultrasonic inspection. As a result, a non-impregnated portion was confirmed. Further, the molded plate was cut, and a cross-section thereof was observed. As a result, a portion not impregnated with the resin was confirmed in the inside of the fiber bundle.
  • a random mat obtained in the same manner as in Comparative Example 1 was heated in a press machine heated at 300°C, at a pressure elevated to 4 MPa for 3 minutes to obtain a molded plate.
  • the resulting molded plate was nearly doubled in area, and the thickness thereof was reduced by nearly half to about 0.3 mm.
  • a fiber flow could be visually confirmed.
  • the tensile modulus of the resulting molded plate in a flow direction and a 90-degree direction to the flow direction were measured.
  • the ratio (E ⁇ ) of the elasticity was 2.33, and it was confirmed that the fibers were largely oriented.
  • this molded plate was heated in a furnace at 500°C for about 1 hour to remove the resin, and thereafter, the ratio of the reinforcing fiber bundles (A) and the average number (N) of fibers were examined. As a result, differences from the measurement results of the random mat described in Comparative Example 1 were not observed.

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Claims (8)

  1. Mat aléatoire comprenant : des fibres de carbone ayant une longueur moyenne de fibre de 5 à 100 mm ; et une résine thermoplastique,
    dans lequel un poids surfacique de fibre des fibres de carbone est de 25 à 3000 g/m2,
    caractérisé en ce que le mat aléatoire comprend un faisceau de fibres de carbone (A) dans une proportion de 30 % en volume à moins de 90 % en volume par rapport à une quantité totale des fibres de carbone, le faisceau de fibres de carbone (A) comportant les fibres de carbone d'un nombre critique de fibres individuelles défini par la formule (1) ou plus, et
    un nombre moyen (N) de fibres de carbone individuelles dans le faisceau de fibres de carbone (A) satisfait la formule (2) : nombre critique de fibres individuelles = 600 / D
    Figure imgb0019
     0 , 7 × 10 4 / D 2 < N < 1 × 10 5 / D 2
    Figure imgb0020
    dans laquelle D est un diamètre moyen de fibre individuelle (µm) du faisceau de fibres de carbone (A).
  2. Mat aléatoire selon la revendication 1,
    dans lequel une quantité existante de la résine thermoplastique dans le mat aléatoire est de 50 à 1000 parties en poids sur la base de 100 parties en poids des fibres de carbone.
  3. Mat aléatoire selon la revendication 1,
    dans lequel la résine thermoplastique est présente sous forme fibreuse ou particulaire.
  4. Mat aléatoire selon la revendication 1, qui a une isotropie dans le plan.
  5. Procédé de production du mat aléatoire selon l'une quelconque des revendications 1 à 4, comprenant :
    la coupe d'un faisceau de fibres de carbone ;
    l'introduction du faisceau de fibres de carbone coupé dans un tube, et l'ouverture du faisceau de fibres de carbone par soufflage d'air sur celui-ci dans le tube ;
    l'écartement et l'aspiration simultanée des fibres de carbone ouvertes, conjointement avec une résine thermoplastique fibreuse ou particulaire, et la pulvérisation des fibres de carbone et de la résine thermoplastique sur une pièce de fixage ; et
    le fixage des fibres de carbone coupées et de la résine thermoplastique qui sont pulvérisées pour former un mat aléatoire.
  6. Matériau composite renforcé de fibres de carbone obtenu en moulant le mat aléatoire selon l'une quelconque des revendications 1 à 3.
  7. Matériau composite renforcé de fibres de carbone selon la revendication 6, dans lequel les fibres de carbone sont orientées aléatoirement dans deux dimensions.
  8. Matériau composite renforcé de fibres de carbone selon la revendication 6, dans lequel un rapport obtenu en divisant une valeur plus grande par une valeur plus petite de module de traction dans deux directions à angle droit l'une de l'autre ne dépasse pas 2.
EP20110857745 2011-02-01 2011-08-31 Matelas aléatoire et matériau composite renforcé par fibres Active EP2671991B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2011019891 2011-02-01
PCT/JP2011/070314 WO2012105080A1 (fr) 2011-02-01 2011-08-31 Matelas aléatoire et matériau composite renforcé par fibres

Publications (3)

Publication Number Publication Date
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JP5436700B2 (ja) 2014-03-05
CN103339308A (zh) 2013-10-02
US20130317161A1 (en) 2013-11-28
WO2012105080A1 (fr) 2012-08-09
KR101444631B1 (ko) 2014-11-04
BR112013019395B1 (pt) 2021-04-06
BR112013019395A2 (pt) 2020-10-27
RU2527703C1 (ru) 2014-09-10
TW201233859A (en) 2012-08-16
KR20130141658A (ko) 2013-12-26
US8946342B2 (en) 2015-02-03
CN103339308B (zh) 2016-02-10
ES2539902T3 (es) 2015-07-07
JPWO2012105080A1 (ja) 2014-07-03
EP2671991A1 (fr) 2013-12-11
TWI448596B (zh) 2014-08-11

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